Publication Date 6/11/07

MODELS
HSG200
A SCOTT FETZER COMPANY
HSG400
801 GLASGOW AVE.
FORT WAYNE, IN 46803
GAS BURNERS
120V/50-60 HZ 220V/50 HZ
US PATENT NO. 4,388,064 PART NO. 62484-001B

WARNING: If the information in these instructions

is not followed exactly, a fire or explosion may result
causing property damage, personal injury or death.
- Do not store or use gasoline or other flammable MEA
vapors and liquids in the vicinity of this or any other MASS.
appliance. ANSI Z21.17

- WHAT TO DO IF YOU SMELL GAS APPROVED

• Do not try to light the appliance. FOR USE CITY
OF NEW YORK
• Do not touch any electrical switch; do not use any MEA 49-83-E
phone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the fire
department.
- Installation and service must be performed by a
qualified, licensed installer, service agency or the gas
supplier. WARRANTY IS VOIDED IF NOT
INSTALLED BY QUALIFIED SERVICE PERSON.

NOTICE
THESE INSTRUCTIONS SHOULD BE AFFIXED TO THE BURNER
OR ADJACENT TO THE HEATING APPLIANCE.
FOR FURTHER INSTRUCTIONS AND WARNINGS,
SEE PAGE 21 OF THIS MANUAL.

SPECIFICATIONS
[SEE PAGE #1]
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 SPECIFICATIONS MODELS
HSG200, HSG400
NATURAL OR PROPANE GAS
NOTE: Dimensions in ( ) are informational only. English values take priority.
HSG200
Maximum Input Capacity - 200 MBtu/HR (211000 kJ)
Minimum Input Capacity - 60 MBtu/HR (63300 kJ)
HSG400
Maximum Input Capacity - 400 MBtu/HR (422000 kJ)
Minimum Input Capacity - 200 MBtu/HR (211000 kJ)
SUPPLY LINE PRESSURE REQUIRED: Natural or Propane 5.5 W.C. (1370 Pa) Minimum, 14.0 W.C. (3487 Pa)
Maximum
AIR TUBE DIAMETER: 4 inches (101.6 mm)
AIR TUBE LENGTHS: HSG200 6 inches (152.4 mm)
(See Fig. 12C for HSG400 6.25 inches (158.75 mm)
Overall Dimensions) HSG200/400 9.00 inches (228.6 mm)
HSG200/400 12.00 inches (304.8 mm)
MOUNTING: Adjustable flange standard (deduct 1 1/8 inch (28.575 mm) from above air tube lengths when using
flange). Optional pedestal mounting.
STANDARD VOLTAGE: 120 VAC / 60 HZ/ 1 Phase
120 VAC / 50 HZ/ 1 Phase (Special motor installed with max capacity reduced 20%)
220 VAC / 50 HZ/ 1 Phase
FLAME SAFETY: 24 VAC Electronic
IGNITION: 7300 VAC Direct Spark
GAS VALVE: 3/4 x 3/4 (19.05 mm x 19.05 mm) NPT 3 Function Redundant 24 VAC
*200 MBtu/HR (211000 kJ) (200,000 BTU [58.62 kW] / HR) or 400 MBtu/HR (42200 kJ) (400,000 BTU [117.24 kW]
/ HR) at sea level. Derate input for altitude over 2000 ft. (609.6 m) by 4% each 1000 ft. (304.8 m) above sea level.
(one gallon (3.79 L) fuel oil = 140 MBtu/HR (14770 kJ)).
CONTENTS
PAGE
SECTION I INSTALLATION .........................................................................................................................................1
A. GENERAL .........................................................................................................................................................2
B. VENTILATION ...................................................................................................................................................2
C. HEATING APPLIANCE INSPECTION ..............................................................................................................2
D. CHIMNEY, FLUE PIPE AND DRAFT CONTROL ..........................................................................................2-3
E. COMBUSTION CHAMBER ...............................................................................................................................4
F. GAS PIPING ......................................................................................................................................................4
G. ELECTRICAL....................................................................................................................................................5
H. MAIN BURNER ORIFICE SIZING AND INSTALLATION .................................................................................5
I. COMBUSTION GAS VALVE...............................................................................................................................6
SECTION II INITIAL START UP................................................................................................................................7-8
SECTION III OPERATION AND TROUBLESHOOTING.........................................................................................9-14
SECTION IV SERVICE ..........................................................................................................................................15-16
PARTS LISTS .............................................................................................................................................................17
EXPLODED VIEW ......................................................................................................................................................18
TECHNICAL INFORMATION......................................................................................................................................19
WARRANTY................................................................................................................................................................20
CONSUMER INSTRUCTIONS ...................................................................................................................................21

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 SECTION I
INSTALLATION
A. GENERAL
The Wayne HSG200 and HSG400 power gas
conversion burners are adaptable to most types of
central heating plants previously fired by power oil
burners. Typical heating plants are gravity and forced
air circulation furnaces, hot water, steam or vapor
boilers. Power burner design makes the HSG200 and
HSG400 well suited for “negative draft” fired
appliances where an oil burner is being replaced.
Installation of these power gas conversion burner
models must conform to local codes, or in their
absence, the American National Standard for the
Installation of Domestic Gas Conversion Burners,
ANSIZ21.8 - and the National Flue Gas Code,
ANSIZ223.1 or current standard year.
NOTICE: ANSI or local installation code compliance is
the sole responsibility of the qualified installer.
B. VENTILATION
The HSG conversion burner models covered by this
manual shall not be installed in an appliance located
where normal air circulation or infiltration is limited in
providing all the air necessary for proper combustion
and draft hood dilution air.
In open basements of homes of normal construction
(without basement storm windows or tight stair doors)
infiltration of combustion air is usually sufficient to
replace that drawn up the flue, so special provisions
are seldom necessary.
When the heating appliance is installed in a tightly closed
room without ventilation openings to outdoors, or other
rooms, provisions shall be made for supplying air for
combustion through special openings, one near the floor
line and the other near the ceiling. Each is to be sized
on the basis of one square inch (645.2mm2) or more of
free area each 1,000 BTU (.29kW) input per hour.
When the building is of unusually tight construction, has
kitchen and/or bathroom ventilation fans which may be
used for exhausting air to outdoors, or has a vented
fireplace, it is recommended that combustion air be
supplied to the furnace room through intakes extending
to the outside of the building and terminating in down
turned fittings, suitably arranged to prevent obstruction
from snow or rain, and including a protecting screen not
smaller than 1/4 inch (6.35mm) mesh.
C. HEATING APPLIANCE INSPECTION
Clean the appliance heat exchanger interior,
combustion chamber and flue connections. Remove
all adhering tars, scale, dirt and soot. Inspect the heat
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exchanger for obvious and potential flue gas leaks.
Cement all joints around the appliance base and
access openings to prevent air and/or flue gas leakage
into or out of the combustion chamber.
Warm Air Furnaces* - Make certain the electrical
characteristics of the fan and limit switch correspond to
those required by this burner and that they are in
proper working order.
Hot Water Boilers* - Make certain water temperature
and altitude gauges, pressure relief valves are in
proper working order.
Steam Boilers* - Make certain the system is pressure
tight, and that the pressure gage and pop off safety
valve are in proper working order. Existing water sight
glass permits clear observation of boiler water level.
*Where applicable, existing temperature of pressure
limit switch or low water cut-off switch operation and
electrical characteristics shall be checked to determine
their compatibility to the gas control circuitry of this
burner.
D. CHIMNEY, FLUE PIPE AND DRAFT CONTROL
The chimney should be inspected for unsafe
conditions such as excessive soot accumulation,
deteriorated masonry, blockage or potential blockage.
NOTICE: No manually adjustable flue pipe damper is
permitted on any gas burner installation.
The chimney should be lined with a corrosion resistant
material. If the chimney is unlined, consult your local
gas utility for recommendations.
WARNING: Under no circumstances should the flue
pipe be connected to the chimney of an open fireplace.
The flue pipe should be sized to carry of the flue gases
as outlined in Figure 1.
INPUT DRAFTHOOD
BTU/HR (kW/HR) FLUE PIPE SIZE
UP to -120 MBH (35.172kW) 5 INCH (127mm) DIAMETER
120 MBtu/HR (35.172kW) - 180 MBH (52.758kW) 6 INCH (152.4mm) DIAMETER
180 MBtu/HR (52.758kW) - 250 MBH (73.275kW) 7 INCH (177.8mm) DIAMETER
250 MBtu/HR (73.275kW) - 320 MBH (93.792kW) 8 INCH (203.2mm) DIAMETER
320 MBtu/HR (93.792kW)- 410 MBH (120.171kW) 9 INCH (228.6mm) DIAMETER
Figure 1
Strict compliance to appropriate codes should be made
regarding flue pipe clearances from combustible materials.
PAGE 2
 Pitch the horizontal run of the flue pipe upward 1/4 inch The draft control should be hood type per Figure 2 or, IF
(6.35mm) per foot (.305m) or more. Run directly to the APPROVED BY LOCAL AUTHORITIES, a single
chimney, fasten joints securely and support horizontal barometric damper suitable for gas firing per Figure 3.
runs to prevent sagging. The draft control should be sized the same as the flue
pipe per Figure 1, and should be located higher than the
If the flue pipe must be extra long, it’s size should be highest part on the appliance flue passage. Refer to the
increased. The horizontal length of the flue pipe should barometric draft regulator manufacturer’s instructions for
not exceed the height of the chimney above the flue complete detail.
connection.
NOTICE: Should the flue pass through a partition,
PITCH HORIZONTAL
DO NOT EXTEND
the draft control must be located in the
RUN 1/4” (6.35mm) MIN.
PER FOOT (.305M) FLUE PIPE BEYOND same room as the heating appliance.
INSIDE OF CHIMNEY
PITCH HORIZONTAL
RUN 1/4” (6.35mm) MIN.
PER FOOT (.305M)
VERTICAL
DRAFT HOOD SINGLE ACTING
BAROMETRIC
HORIZONTAL DRAFT CONTROL
DRAFT HOOD

REDUCER CORROSION
RESISTANT LINING

CLEANOUT

SELECT EITHER CHIMNEY

HORIZTONAL OR CLEANOUT
VERTICAL DRAFT HOOD

DRAFT HOOD POSITONS

Figure 2 BAROMETRIC DRAFT

CONTROL POSITION
Figure 3

TO PROTECT PROPERLY
LOCATE END OF BURNER
TUBE. POSITION TUBE 1/2”
(12.7mm) SHORT OF INSIDE
OF COMBUSTION
CHAMBER

FORCED AIR FURNACE

Figure 4

EXISTING OR
ADDED TARGET
TO BACK OF COMBUS- EXISTING
TION CHAMBER PREFABRICATED
COMBUSTION
CHAMBER LINER

TO PROTECT PROPERLY TO PROTECT PROPERLY

LOCATE END OF BURNER LOCATE END OF BURNER
TUBE. POSITION TUBE 1/2” TUBE. POSITION TUBE 1/2”
(12.7mm) SHORT OF INSIDE (12.7mm) SHORT OF INSIDE
OF COMBUSTION OF COMBUSTION
CHAMBER CHAMBER

HOT WATER OR STEAM BOILER WITH HOT WATER OR STEAM BOILER WITH
COMBUSTION CHAMBER TARGET COMBUSTION CHAMBER LINER
Figure 5 Figure 6
PAGE 3

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 E. COMBUSTION CHAMBER F. GAS PIPING
A combustion chamber is normally required to NOTICE: All piping must comply with state and/or
local codes. The available gas supply pressure
protect non-heat transfer surfaces, and to provide a
should be within minimum and maximum pressures
radiant bed for rapid heat transfer to the primary
shown in the burner specifications. If the gas supply
surfaces of the heat exchanger. If in good condition, pressure exceeds the 14” W.C. (3.5 k Pa) maximum,
the existing combustion chamber can be used. an intermediate main gas regulator must be installed
A full combustion chamber liner is recommended for ahead of the main gas manual shut off valve shown
warm air furnaces, (see Figure 4), and a target wall in Figure 8.
or full combustion chamber liner is recommended WARNING: Failure to install the intermediate gas
for wet leg cast iron or steel boilers. (See Figures 5 regulator will result in gas leakage from burner gas
and 6). If a built-up chamber is necessary, use valve.
2300˚ F (1260˚C) minimum insulating fire-brick or A drip leg or sediment trap must be installed in the
fiberfrax. supply line to the burner. See Figure 8.
A pipe union shall be installed in the gas line
THE BURNER AIR TUBE MUST NOT BE adjacent to, and upstream from, the main gas
ALLOWED TO EXTEND INTO THE CHAMBER manual shutoff valve. See Figure 8.
PROPER; IT MUST BE SET 1/2 INCH (12.7mm) The gas supply piping to the burner should branch
SHORT OF THE INSIDE SURFACE. off from the main gas supply line as close to the gas
Before permanently securing the burner to the meter as possible. Do not connect to the bottom of
heating appliance with either the adjustable mounting a horizontal section. See Figure 9 for gas supply
flange or pedestal or cementing around the air tube pipe sizes.
in the combustion chamber opening, check that the Use new black iron pipe and malleable fittings free
burner head assembly is free of foreign materials and of burrs and defects. Use pipe joint compound
that the sensor and electrode probes have not been resistant to liquefied petroleum gases.
damaged or repositioned, see Figure 13. A 1/8” (3.175mm) NPT plugged tapping accessible
for test gauge connection shall be provided
INPUT PREFERRED immediately upstream of the gas supply connection
BTU/HR for determining gas supply pressure to the burner.
kW/Hr WIDTH”(mm) X LENGTH”(mm) DIAM.” (mm) Test new supply piping for leaks. CAUTION:
50 MBtu/HR (14.655kW) 7 (177.8) X 7 (177.8) 8 (203.2) DURING PRESSURE TEST FOR LEAKS IN GAS
75 MBtu/HR (219.825kW) 7 1/2 (190.5) X 7 1/2 (190.5) 9 (228.6) SUPPLY PIPING, THE BURNER MUST BE
100 MBtu/HR (293.1kW) 12 (304.8) X 12 (304.8) 13 (330.2) DISCONNECTED TO PREVENT EXPOSING THE
150 MBtu/HR (439.65kW) 12 (304.8) X 15 (381) 14 (355.6) COMBINATION GAS VALVE TO PRESSURES
200 MBtu/HR (586.2kW) 13 (330.2) X 17 (431.8) 15 (381) OVER 1/2” (3447 PaG) PSIG. POSSIBLY
250 MBtu/HR (732.75kW) 13 (330.2) X 18 (457.2) 16 (406.4) DAMAGING THE VALVE AND VOIDING THE
300 MBtu/HR (879.3kW) 13 (330.2) X 20 (508) 18 (457.2) BURNER WARRANTY.
350 MBtu/HR (1025.85kW) 14 (355.6) X 21 (533.4) 20 (508)
400 MBtu/HR (1172.4kW) 15 (381) X 22 (558.8) 21 (533.4)
CAPACITY - MBtu/HR (kJ)
RECOMMENDED COMBUSTION PIPE TYPE
SIZE OF GAS LENGTH OF PIPE
CHAMBER SIZES 15 (381mm) 30 (762mm) 45 (1143mm) 90 (2286mm)
Figure 7 3/4 Propane 400 250 200
(19.05mm) (422000kJ) (263750kJ) (211000kJ)
1 Natural 400 250 200
MANUAL SHUTOFF VALVE
(25.4mm) (422000kJ) (263750kJ) (211000kJ)
Propane 400 350 250
(422000kJ) (369250kJ) (263750kJ)
1/8” (3.175mm) N.P.T.
PLUGGED TAPPING 1 1/4 Natural 400 400 300
DIRECTION
OF FLOW
PRESSURE GAGE PORT (31.75mm) (422000kJ) (422000kJ) (316500kJ)
Propane 400 400
TEE UNION (422000kJ) (422000kJ)
1 1/2 Natural 400
(38.1mm) (422000kJ)
3” MIN. CONTROL MANIFOLD CAPACITIES SHOWN ARE FOR A TOTAL PRESSURE
(76.2mm)
PIPE CAP
DROP OF 0.3” W.C. (74.73Pa) FOR 0.5” W.C. (124.55Pa)
PRESSURE DROP, MULTIPLY CAPACITY SHOWN BY 1.3.
DRIP LEG
FOR HIGHER PERMISSIBLE PRESSURE DROPS,
SUPPLY LINE CONNECTION CONSULT YOUR UTILITY.
TO BURNER
Figure 8 SUPPLY PIPE CAPACITIES IN MBtu/HR (kW)
Figure 9
PAGE 4

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 G. ELECTRICAL H. MAIN BURNER ORIFICE SIZING
AND INSTALLATION
The installation must be wired and GROUNDED in
accordance with local codes or in their absence, The HSG200 and HSG400 power gas conversion
with the National Electric Code ANSI/NFPA No. 70- burners are approved for use with natural and
1987 or latest edition. propane gas only.
For the 120 VAC wiring to the burner, use solid The HSG200 and HSG400 burner models are
copper conductor wire not lighter than #14 AWG. If shipped labeled and orificed for natural gas. To
a fused disconnect is used, it should be fused for a convert to propane gas and/or increase BTU/HR
minimum of 15 amps. (kcal/Hr) input on natural or propane gas, an orifice
CAUTION: Each installation must include suitable kit is supplied with each burner with the orifices
limit controls. Existing oil burner combination limit shown in Figure 10.
and operating controls are normally not suitable for When selecting a desired BTU/HR (kcal/Hr) input,
gas burner use. figure 140,000 BTU’s per gallon of oil input. For
CAUTION: The burner is equipped with it’s own 24 example: furnace or boiler rating of 0.75gph at 100
VAC transformer. Do not add any 24 VAC power psig. The 0.75 x 140,000 = 105,000 BTU’s input
consuming device in the 24 VAC control circuit of rate. It may be possible to reduce the firing rate on
the burner, as it could overload the transformer. natural or propane gas 15% to 20%, as most older
appliances are oversized for the heating load.
Set the room thermostat “heat anticipator” for the
total current draw of the 24 VAC burner operation (2.83875L x 9356 kcal = 26559.35 kcal)
circuit. (HSG200 0.55 amps, HSG400 0.7 amps) To remove or interchange main orifice discs refer to
CAUTION: Label all wires prior to disconnection Figure 15 (Page 16).
when servicing controls. Wiring errors can cause 1. Remove slotted orifice cap, Item #40, making
improper and dangerous operation. sure orifice cap gasket, #39, stays attached to
Verify proper operation after servicing. orifice cap and is not damaged.
NOTE: If any of the original burner wiring must be 2. Remove orifice spring, Item #38, to access and
replaced, it must be replaced with #18 remove orifice disc, Item #42.
AWG 105 degrees C wire or equivalent. 3. Install desired orifice from Figure 10, making
Section 3- Operation and Troubleshooting for sure it is seated flat in the orifice holder, Item
applicable burner wiring diagrams. #37.
4. Replace orifice spring and securely tighten
orifice cap against orifice cap gasket in orifice
holder.
ORIFICE MANIFOLD PRESSURE
SIZE & DRILL 2.0” (498.2Pa) 3.0” (747.3Pa) 4.0” (996.4Pa)
HSG200 NATURAL GAS
#29 - .136 (3.4544mm) 50,000 BTU (52750kJ) 64,000 BTU (67520kJ) 76,500 BTU (80707.5kJ)
#8 - .199 (5.0546mm) 74,000 BTU (78070kJ) 95,000 BTU (100225kJ) 116,000 BTU (122380kJ)
J - .277 (7.0358mm) 112,000 BTU (118160kJ) 138,000 BTU (145590kJ) 164,000 BTU (173020kJ)
Q - .332 (8.4328mm) 160,000 BTU (168800kJ) 206,000 BTU (217330kJ)
HSG200 L.P. GAS
#30 - .128 (3.2512mm) 49,000 BTU (51695kJ) 58,500 BTU (61717.5kJ) 68,200 BTU (71951kJ)
#27 - .144 (3.6576mm) 66,000 BTU (69630kJ) 78,000 BTU (82290kJ) 92,000 BTU (97060kJ)
#15 - .180 (4.572mm) 82,000 BTU (86510kJ) 112,500 BTU (118687.5kJ) 136,000 BTU (143480kJ)
D - .246 (6.2484mm) 131,000 BTU (138205kJ) 187,500 BTU (197812.5kJ) 243,000 BTU (256365kJ)
HSG400 NATURAL GAS
T - .358 (9.0932mm) 200,000 BTU (211000kJ) 248,000 BTU (261640kJ) 285000 BTU (300675kJ) NOTE: For
15/32 - .468 (11.8872mm) 265,000 BTU (279575kJ) 343,000 BTU (361865kJ) 400,000 BTU (422000kJ) 50 cycle
HSG400 L.P. GAS application
K - .281 (7.1374mm) 190,000 BTU (200450kJ) 242,500 BTU (255837.5kJ) 295,000 BTU (311225kJ) derate input
Q - .332 (8.4328mm) 242,500 BTU (255837kJ) 332,500 BTU (350787.5kJ) 400,000 BTU (422000kJ) by 15%

HSG SERIES POWER GAS CONVERSION BURNERS

ORIFICE CHART
Figure 10
PAGE 5

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 I. COMBINATION GAS VALVE
The 24 VAC combination gas valve serves three (3)
functions: (1) manual gas shut-off, (2) main gas
flame pressure regulator, (3) automatic electric
redundant (double seated) gas shut off. (See
Figure 11)
The correct operating manifold orifice pressure range
for both natural and propane gas is 2.0” W.C.
(498.2Pa) minimum to 4.0” W.C. (996.4Pa)
maximum. By adjusting the pressure regulator
between 2.0” W.C. (498.2Pa) and 4.0” W.C.
(996.4Pa) on either natural or propane gas, a wide
input range can be achieved with a single orifice size.
If the desired input rating cannot be obtained within
the above manifold orifice pressure adjustment
range, the next size larger or smaller orifice should be
used. (Refer to orifice chart Fig. 10.)
J. PRESSURE REGULATOR ADJUSTMENT
The combination gas valve pressure regulator,
which has an outlet pressure setting range of
1/8” (3.175mm) NPT
PRESSURE TAP
PLUG
Figure 11
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approximately 2.0” W.C. (498.2Pa) to 4.0” W.C.
(996.4Pa) is factory set at 3.5” W.C (871.85Pa).
When pressure adjustment is required for setting
input capacity with a selected orifice from Figure 10,
remove the regulator cap for access to the slotted
adjustment screw. Turning the screw counter
clockwise reduces manifold orifice pressure,
clockwise increases the pressure.
NOTE: MANIFOLD PRESSURE ADJUSTMENTS
CAN ONLY BE MADE WITH THE
BURNER RUNNING AND THE GAS ON.
The 1/8” (3.175mm) NPT pressure tap for orifice
manifold pressure measurement is located on the
outlet side of the combination gas valve. Use a “u”
tube manometer or dial type pressure gauge,
scaled from “0” zero to 15.0” W.C. (3736.5Pa) to
read pressure (See Figure 11).
1/8” (3.175mm) NPT
PRESSURE TAP PLUG
HSG 200/400 GAS VALVE
HONEYWELL VR8305
PAGE 6
 SECTION II
INITIAL START UP
1. NOTE: Read the applicable sequence of the primary air damper open or closed to visually
burner/primary gas control operation in obtain a blue flame with well defined orange or
Section 3 Operation and Troubleshooting yellow tips for natural gas, or well defined yellow tips
before proceeding. for propane gas.

2. Depress the combination gas valve manual control 12. After the burner has been in operation for at least 10
knob and turn to “OFF” position. minutes, assuring combustion chamber and heat
exchanger are fully warmed, take combustion
3. Adjust the primary air and off-cycle damper to the analysis flue gas samples just ahead of the draft
start up settings shown in Figure 12A and 12B. control in the flue pipe.
4. On new gas line installations, air may be trapped in NOTE: ALWAYS USE RELIABLE COMBUSTION
the line, the burner may experience several TEST INSTRUMENTS. BEING
lockouts until all the air is purged from the lines. PROFICIENT IN THE USE OF THESE
INSTRUMENTS AND INTERPRETING
5. Turn on the main electrical power and set the
THEIR DATA IS NECESSARY FOR SAFE,
thermostat or operation control to call for heat.
RELIABLE AND EFFICIENT BURNER
Allow the burner to run a MINIMUM of 5 minutes to
OPERATION.
purge combustion chamber and appliance heat
exchanger. 13. Perform the following combustion analysis. All
adjustments below must be made with the following
6. Set the thermostat or operating control below room
instruments: draft gauge, O2 or CO2 analyze and
temperature, shutting the burner “OFF” 1 minute to
RESET the primary control. CO tester.

7. Depress the combination gas valve manual control A. Adjust the primary air damper to provide about
now and turn to “ON” position. 25% excess combustion air. Confirm this by
checking the flue gas for its FREE OXYGEN
8. Set the thermostat or operating control to call for (O2) or CARBON DIOXIDE (CO2) PERCEN-
heat. The burner will start and go through the TAGES with a test instrument. Free oxygen
applicable sequence of burner/primary gas control should be about 4.5%, or carbon dioxide should
operation, refer to step 1. be about 9.5% for natural gas, 12.1% for
propane gas.
9. Once burner is running adjust the orifice manifold
pressure regulator as described in paragraph J - B. CARBON MONOXIDE - Should be checked for
Pressure Regulator Adjustment. its presence in the flue gas. This percentage
should not exceed .04% (or 400 PPM).
10. A more accurate BTU (kW) input can be determined
by using the NATURAL gas service meter with the C. NOTE: Check overfire draft and adjust to
burner only on (all other gas appliances should be NEGATIVE -.01 (2.491Pa) to -.02 (4.982Pa)
off). The hand on the gas meter dial with the lowest inches w/c during burner operation.
cubic feet valve (fastest revolving dial), should be
clocked for one complete revolution and use the
following formula.

3600 x cubic ft. (m3)pre revolution x btu (kW) valve/cub ic ft (m3) = BTU/HR (kW/Hr)
seconds per revolution

EXAMPLE: 3600 x 1 x 1000 (.2931kW) = 300,000 BTU/HR (87.93 kW/HR)

12

11. After the desired input has been obtained, re-adjust

PAGE 7

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 D. The flue gas temperature should be between
325˚F (162.78˚C) and 550˚F (287.78˚C)for
domestic gas conversion burners. Higher flue
gas temperatures indicate overfiring or
excessive draft through the appliance. Lower
flue gas temperatures may cause excessive
condensation and indicate underfiring. Consult
your local utility or the appliance manufacturer
for acceptable flue gas temperatures.
CAUTION: IF THE BURNER BTU/HR (kW/Hr)
INPUT IS CHANGED, REPEAT STEP 13
14. FILL OUT THE INSTALLATION COMBUSTION
DATA TAG AND AFFIX IT TO THE BURNER OR
CONVERTED APPLIANCE.
SUGGESTION: All new installations should be
reinspected for proper combustion and burner
operation after one or two weeks of normal
operation.
For subsequent normal starting and shut off
procedure, refer to the “Consumer Instructions” in
the back of this manual or the instruction plate
attached to the burner.

3/8” (9.525mm)

HSG200 SET AT NO. 1

HSG400 SET AT NO. 1 1/2

Figure 12A Figure 12B

IMPORTANT
THESE SETTINGS ARE FOR INITIAL STARTUP ONLY, AND MUST BE
READJUSTED FOR COMBUSTION EFFICIENCY.

Figure 12C

PAGE 8

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 SECTION III
OPERATION AND TROUBLESHOOTING
SEQUENCE OF OPERATION - HSG SERIES POWER GAS
CONVERSION BURNER UTILIZING HONEYWELL S89F
GAS PRIMARY P/N 62759-002 W/BUILT IN 30 SECOND PREPURGE
On a call for heat, voltage (24V) is applied to motor start the flame rod will provide flame monitoring to the S89F
relay and air switch. Once the fan motor reaches gas control primary for the remainder of the heat cycle.
operating rpm combustion air pressure is sensed by the If the flame should be extinguished during the heat
air proving switch and closes the switch contacts cycle, the S89F gas control primary will go into the 30
energizing the S89F gas primary control. second prepurge and 8 second safe start check, then
re-energize the gas valve and ignition transformer in an
THE S89F gas primary control has an internal 30 attempt to establish the main burner flame. If this does
second prepurge timer. After the initial 30 second not occur within the 4 second trial for ignition period, the
prepurge, an internal 8 second safe start check of the S89F gas primary control will go into lockout de-
S89F will commence. Once this is successfully energizing the gas valve and ignition transformer.
completed, the S89F simultaneously energizes the gas
valve and ignition transformer. Gas flows and the To restart the system, the main power or thermostat
transformer produces an approximate 7300 volt spark must be de-energized momentarily, then re-energized.
end point grounded at the burner head establishing If at any time during the heat cycle, there is an
main burner flame. insufficient supply of combustion air to the burner, the
air switch will open, putting the system into lockout
At the start of each heat cycle, there is a trial for ignition closing the gas valve.
period of four (4) seconds duration. Normally, burner
flame will be established before the end of this period.
Once the flame is established, sparking will cease and

HSG POWER GAS BURNER

WITH HONEYWELL S89F GAS PRIMARY

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 SEQUENCE OF OPERATION - HSG SERIES
POWER GAS CONVERSION BURNER UTILIZING
HONEYWELL S89E GAS PRIMARY P/N 62758-002 W/ EXTERNAL
30 SECOND PREPURGE TIMER P/N 62388-001 AND RESISTOR P/N 62530-001
On a call for heat, voltage (24V) is applied to the motor
start relay and air switch. The motor relay pulls in the
motor. After the motor reaches speed, the combustion
air blower closes the air proving switch contacts,
energizing the external 30 second prepurge timer. After
the 30 second prepurge timing, the S89E is energized.
The S89E gas primary control has an internal 8 second
safe start check. After the initial 30 second prepurge
provided by the external timer, the S89E gas primary
control is energized, the 8 second safe start check will
commence. Once this is accomplished, the S89E
activates the gas valve allowing gas to flow to the burner
head. Simultaneously, the S89E control energizes the
ignition transformer, producing an approximate 7300
volt spark end point grounded at the burner head,
establishing main burner flame.
At the start of each heat cycle, there is a trial for ignition
period of four (4) seconds duration. Normally, burner
flame will be established before the end of this period.
Once the flame is established, sparking will cease and
the flame rod will provide flame monitoring to the S89E
gas primary control for the remainder of the heat cycle.
When utilizing the S89E gas primary control with the
eternal 30 second prepurge timer, a 10K ohm resistor is
wired in parallel between the output terminal of the 30
HSG POWER GAS BURNER
WITH HONEYWELL S89E GAS PRIMARY
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second prepurge timer and the input terminal to the
S89E gas primary control. The function of this resistor
is to keep a load on the output terminal of the external
30 second prepurge timer, after the initial call for heat
and 30 second start prepurge and 8 second safe start
check.
This promotes simultaneous re-ignition of the main
burner flame after the S89E’s 8 second safe start check,
overriding the 30 second prepurge. This is desirable in
oven or similar applications where temperatures cannot
vary drastically.
Should the flame be extinguished during the heat cycle,
the S89E primary ignition control will go into the 8
second safe start check after which time it will re-
energize the gas valve and ignition transformer in an
attempt to re-establish the main burner flame. If this
does not occur within the 4 second trial for ignition
period, the S89E gas primary control will go into lockout
de-energizing the gas valve and ignition transformer. To
restart the system, the main power or thermostat must
be de-energized momentarily, then re-energized. If at
any time during the heat cycle, there is insufficient
supply of combustion air to the burner, the air switch
contacts will open, putting the system into lockout
closing the gas valve.
PAGE 10
 FLAME SENSING

The Honeywell S89 series primary ignition controls
utilize the flame current rectification principal for main
burner flame sensing.
The flame rectification phenomenon occurs as follows.
The ignited gas flame causes the immediate
atmosphere around the flame to become ionized (gas
atoms become electrically charged). The ionization
causes the atmosphere around the flame to become
electrically conductive. An AC voltage output from the
control sensing circuit is routed through the flame
sensor probe. When the sensor probe and the burner
head are both in contact with a properly adjusted flame,
the burner head with its larger surface attracts more free
electrons, thus becoming negatively charged. The
sensor probe with its small surface area gives up free
electrons, thus becoming positively charged. The free
electrons from the AC voltage in the sensor probe flow
through the ionized gas flame to the grounded burner
head. As the AC current passes through the gas flame,
it is rectified into a DC current flowing back to the
grounded side of the sensing circuit. The flame in
actuality is a switch. When the flame is present, the
switch is closed allowing current to flow through the
sensing circuit of the control. When no flame is present,
the switch is open with no current flowing through the
sensing circuit of the control.
The DC current flow is measured in units called DC
microamperers. A steady DC microamp current of .8
minimum (and steady) or higher through the sensing
circuit of the primary ignition control is sufficient to keep
the burner running without a safety lockout. See Figure
13 for sensor probe and electrode dimensional settings,
Figure 14 for flame current measurement.

Figure 13

Figure 14

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 PAGE 12

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 PAGE 13

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 PAGE 14

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 SECTION IV
SERVICE
Caution: Make sure the main manual, combination
valves and main power switch are turned
off before opening burner or removing any
parts for service.
A. BURNER HEAD AND
ELECTRODE/SENSOR ASSEMBLY
The burner head, electrode, sensor probe,
combination valve, orifice housing and housing
cover are part of the gas train assembly which can
be removed as one unit. (See Figure 15)
1. Disconnect gas line from combustion gas valve
inlet, flame sensor lead wire from gas primary,
gas valve lead wires from gas valve operator
and (orange) ignition lead wire from ignition
transformer ignition lead wire.
2. Remove the two 1/4” (6.35mm) hex slotted
screws on the top front of the housing cover and
the two 5/16” (7.9375mm) hex slotted screws
on the left and right side back of the housing
cover.
3. To remove gas train assembly, gently lift up rear
of housing cover pulling rearward slightly on the
drawer assembly gradually positioning the rear
of the drawer assembly upward 90 degrees
(1.57RAD). Gently extract burner head and
electrode/sensor assembly out opening in
housing taking extreme care to not dislocate or
damage electrode or sensor probe.
4. When servicing, clean burner head ports,
electrodes and sensor probe. Inspect the
sensor probe and electrode wires and porcelain
insulators carefully for hairline cracks which
might provide an electrical leak path that could
short out the ignition spark, or flame signal.
5. Examine the electrode and sensor probe for
any serious corrosion or deterioration of metal
at the tips. Check for proper dimensional
settings of the sensor probe and electrode (see
Figure 13). Adjust and/or replace these
assemblies as necessary. Make sure that the
ignition and sensor probe wires go to the
correct electrodes and the ignition wire boot is
in place over the electrode porcelain.
6. Make sure that the burner tube end is properly
positioned in the combustion chamber entry. It
must be set 1/2” (12.7mm) short of the inside
face of the combustion chamber as shown in
figures 4, 5 or 6.
B. AIR PROVING SWITCH
The air proving switch is mounted to the housing
cover with (2) #6 self tapping screws under the gas
valve. A clear plastic tube, protected by a spring
cover, is connected to the barbed fitting on the
pressure switch while the other end is connected to
a brass barbed fitting. The plastice tube allows
pressurized air from the blower housing to travel to
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the pressure switch causing the diaphragm contacts
to close thus completing the circuit.
The function of the air proving switch is to ensure
sufficient combustion air is being developed by the
blower motor and blower wheel. Should the blower
motor fail or the blower wheel malfunction, the
burner gas valve will shut off.
1. The air proving switch should never require
maintenance. However, should nuisance
lockouts occur, the pressure switch can be
checked. This is done by disconnecting the
yellow and white leads from the Air Proving
switch and jumpering the leads together. If the
burner functions correctly, the switch needs to
be replaced.
WARNING: If a jumper is used to check the switch it
must be removed or an unsafe condition
can occur resulting in death or property
damage.
2. As mentioned above, the switch should never
require maintenance. However a pinched tube
will shut off the flow of pressurized air to the
diaphragm creating a failure made similar to
bad Air Proving switch. Always check to ensure
that the clear tubing is not pinched. Make sure
the spring cover is reinstalled over tube.
3. Switch is mounted in the horizontal position with
terminals up from factory. Final burner mounting
should maintain horizontal switch position.
WARNING: Damage to internal components of
burner may result, if burner is mounted in other
than horizontal position.
C. COMBUSTION AIR BLOWER AND MOTOR
1. Cleaning of the combustion air blower is
indicated if the blades show an accumulation of
dust and lint, or if the character of the flame
indicates a deficiency of combustion air.
2. The side plate, motor and blower wheel are
removed as one assembly. Disconnect the
motor wire inside the junction box beneath the
ignition transformer. Remove the four (4) 5/16”
(7.9375mm) hex slotted screws securing
sideplate to fan housing.
CAUTION: Do not remove blower wheel from motor
shaft during periodic cleaning.
3. Should removal of the blower wheel be
necessary for cleaning or replacement of it or
the motor, the blower wheel must be positioned
correctly on the motor shaft. (Figure 16)
HSG200 blower wheel p/n 21664 is positioned
2 1/16” (52.3875mm) measured from the blower
wheel inlet ring face to the side plate face.
HSG400 blower wheel p/n 21642 is positioned
2 3/16” (55.5625mm) measured from the blower
wheel inlet ring face to the side plate face.
 DRAWER ASSEMBLY
Figure 15

PART NUMBER DIM “A”

21664
HSG200 2 1/16”
5 1/4 O.D. (52.3875mm)
(133.35mm)
21642
HSG400 2 3/16”
5 1/2 O.D. (55.5625mm)
(139.7mm)

MOTOR/BLOWER ASSEMBLY
Figure 16

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 PARTS LIST - MODEL HSG 200/400 SEE FIG. 15 & FIG. 17
Item Part No. Description
1. 100934-001 Burner Housing
2. 62576-003 Air Tube - HSG200 6" (152.4mm)
63270-004 Air Tube - HSG400 6 1/4" (158.75 mm)
62576-015 Air Tube - HSG200 9" (228.6mm)
63270-015 Air Tube - HSG400 9" (228.6mm)
62576-027 Air Tube - HSG200 12" (304.8mm)
63270-027 Air Tube - HSG400 12" (304.8mm)
63270-028 Air Tube - HSG400 15" (381 mm)
3. 62393-001 Air Cone - (HSG200 only)
4. 21724-011 Adjustable Flange Assembly (includes gasket)(not shown)
5. 100428-002 Flange Gasket (not shown)
6. 21664 Blower Wheel HSG200 5 1/4" OD (133.35mm)
21642 Blower Wheel HSG400 5 1/2" OD (139.7mm)
7. 21658 Side Plate (Used with 20627 and 20627-004 Motors Only)
8. 20627 Motor, Split Phase 1/7 (.107kW) or 1/8 (.093kW) HP 3450 RPM 115V/60
20627-004 Motor, Split Phase 1/7 (.107kW) HP 2850 RPM 230V/50Hz (220V/50Hz)
9. 100373-002 Combustion Air Inlet Damper
10. 62408-001 Control Box (S89E & S89F) Used with Primary safety Control
11. 62388-001 30 Sec. Prepurge Time P/N 62758-002
62530-001 Resistor Wire Assy. (Special limit applications only)
12. 60186-004 24 Volt Transformer 120V
63005-002 24 Volt Transformer 220V
100450-001 Bushing
13. 62406-002 Motor Relay
14. 62759-002 Primary Safety Control H'Well S89F w/30 Sec Prepurge (220V/50Hz)
62758-002 Primary Safety Control H'Well S89E w/o 30 Sec Prepurge
(Special Limit Applications Only)
15. 100377-002 Damper Indicator Pointer
16. 100429 Damper Decal
17. 63263-005 Pressure Switch
63272-005 Pressure Switch Conversion Kit
63935-001 Pressure Switch (220V/50Hz)
18. 60178-002 Thermostat Terminal Strip
19. 100372 Adjustment Arm Off-Cycle Damper
20-21. 100371-KIT Off-Cycle Damper Kit
22. 21319 Junction Box (under Ignition Transformer)
23. 61843 Lighting Plate
24. 62407-001 Ignition Transformer 7500V
64051-001 Ignition Transformer 220V/50Hz Danfoss
25. 62391-002 Electrode Assembly
26. 62390-002 Sensor Probe Assembly
27. 62387-001 Insulator Bushing (not shown)
28. 62575-002 Chamber/Manifold - HSG200 6" (152.4mm)
62575-001 Chamber/Manifold - HSG400 6 1/4" (158.75 mm)
62575-014 Chamber/Manifold - HSG200 9" (228.6mm)
62575-012 Chamber/Manifold - HSG400 9" (228.6mm)
62575-026 Chamber/Manifold - HSG200 12" (304.8mm)
62575-024 Chamber/Manifold - HSG400 12" (304.8mm)
62575-031 Chamber/Manifold - HSG400 15" (381 mm)
29. 62419-001 Clip, Electrode Bracket
30. 61951-001 Ignitor Support Parts Kit
31. 62411-028 11" (279.4mm) Sensor Wire - 6" (152.4mm), 6 1/4" (158.75mm) Burner
62411-030 14" (355,6mm), Sensor Wire - 9" (228.6mm), 12" (304.8mm) Burner
62411-068 17" (431,8mm), Sensor Wire - 15" (228.6mm) Burner
64096-001 Sense Wire – 330mm Cable (220V/50Hz)
32. 62909-001 8" (203.2mm) Ignition Wire - 6" (152.4mm), 6 1/4" (158.75mm) Burner
62909-003 14" (355.6mm) Ignition Wire - 9" (228.6mm), 12" (304.8mm) Burner,
15” (228.6mm) Burner
64095-001 Ignition Wire – 500mm Cable (220V/50Hz)
33. 62404-002 Top Plate/Housing Cover
34. 62304 Strain Relief Bushing/Ignition Wire
35. 62402-001 Orifice Housing
36. 62410-001 Orifice Spring
37. 62401-001 Orifice Gasket
38. 62385-001 Orifice Cap
39. 62374-004 Gas Valve Honeywell VR8305M 4801
40. 62459-001 Orifice Package - HSG200 (not shown)
62459-002 Orifice Package - HSG400 (not shown)
41. 21760-001 Optional Pedestal Mounting (not shown)
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 TECHNICAL INFORMATION
“Troubleshooting Guide”
NUISANCE LOCKOUTS/FLAME SENSING PROBLEMS - HSG200 & HSG400 GAS BURNERS
Wayne’s HSG series direct spark ignition (DSI) gas
burners prove flame through the process of flame
rectification. Flame rectification is achieved by placing a
small voltage on the flame sensing probe. When the
probe is surrounded by flame, the voltage on the probe
“leaks” to ground through the flame, resulting in an
electrical current. This current is interpreted by the
ignition control as the presence of flame.
One of the most common problems with gas appliances
utilizing this type of electronic flame sensing system is
the “nuisance lockout”. Lockouts are not generally due
to the burner failing to ignite, but rather simply the failure
of the system to sense the establishment of flame.
Should this situation exist for a period of time longer
than the ignition control’s state lockout timing, the
control will shut down or go into permanent lockout. The
only way to get the burner to recycle is to break, and
then reinstate power to the burner.
The following situations can lead to flame sensing
problems and can be checked without
disassembling the burner:
• The burner is not properly grounded to “earth
ground” on the line voltage.
• The ignition control is not properly grounded to the
burner itself. Using an ohmmeter, check the wire
attached to both parts for good contact and
continuity.
• The burner ignition control is polarity sensitive. The
polarity of the incoming line voltage may be
reversed. Verify that black and white wires are hot
and neutral respectively, and that they are
connected to the corresponding black and white
wires on the burner.
The remaining checks and/or adjustments require
removal of the gas train:
• The connections from the “SENSE” terminal of the
ignition control to the end of the flamerod may be
broken at some point. Check all quick connect
terminations and connections. Check the continuity
with an ohmmeter while flexing wires to assure no
hidden conductor breakage exists. If replaced,
wiring must be of equal, or heavier gauge and
equal, or better temperature rating.
• The flamerod probe may be grounded out. Assure
that the flamerod probe is not touching the burner
head. The probe should be positioned in the center
of the clearance groove on the outer edge of the
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burner head with approximately 1/16” (1.5875mm)
clearance from the head. The probe must not be
positioned to far away from the head as this may
result in grounding out of the probe against the
inside surface of the air tube.
• The flamerod probe should be free of soot and
creosote. Deposits may insulate the probe, leading
it not to pass the electrical charge to the flame. The
probe can be cleaned with steel wool, emery paper
or fine sandpaper. NOTE: This is the leading cause
of nuisance lockouts in dual-fuel wood/gas fired
appliances.
• The flamerod probe may be burned away. Check it
against dimensions on the ELECTRODE AND
FLAMEROD PROBE SETTINGS drawing.
• The dimensional location of the flamerod probe may
be incorrect, or the probe may be bent out of shape.
Check it against dimensions on the ELECTRODE
AND FLAMEROD PROBE SETTINGS drawing and
adjust if necessary.
• The spark electrode gap may be incorrect, resulting
in no spark or an inadequate spark that will not
ignite the gas properly. Check the electrode gap
against the ELECTRODE AND FLAMEROD
PROBE SETTINGS drawing and adjust if required.
• The high tension lead conductor from the ignition
transformer to the tip of the spark electrode may be
broken, preventing the high voltage current from
getting to the electrode tip. Check all connections
thoroughly and/or check to continuity of the lead
wire assembly with an ohmmeter.
Once all of the items listed previously have been
carefully checked and corrected if necessary, reinsert
the gas train assembly into the burner. NOTE: Be
careful not to bend the air proving switch sail arm (if so
equipped) or accidentally reposition either the flamerod
probe or electrode during reinstallation of the gas train
assembly.
If, after all of the above listed items have been carefully
checked, the burner still fails to work, it is due to one or
more of the following problems:
1. Unit sparks and fires but will not stay lit. Ignition
control module is malfunctioning and must be
replaced.
2. Unit does not spark. Ignition transformer is bad and
must be replaced.
 LIMITED WARRANTIES FOR OIL AND
GAS BURNERS, MADE BY WAYNE AND
USED IN RESIDENTIAL INSTALLATIONS
WAYNE COMBUSTION SYSTEMS (“WAYNE”) warrants
to those who purchase its Oil Burner Models for resale or
for incorporation into a product of resale, that its burner is
free from defects in material and workmanship under
normal use and service for thirty-six (36) months from the
date of manufacture. ALL GAS BURNERS manufactured
by “WAYNE” will be similarly warranted for eighteen(18)
months from date of manufacture except where original
manufacture offers a greater warranty. (Reference #6
below) THESE LIMITED WARRANTIES DO NOT APPLY
UNLESS THE BURNER COVERED BY IT IS PROPERLY
INSTALLED BY A QUALIFIED, COMPETENT
TECHNICIAN, WHO IS LICENSED WHERE STATE
AND/OR LOCAL CODES PREVAIL, AND WHO IS
EXPERIENCED IN MAKING SUCH INSTALLATIONS, IN
ACCORDANCE WITH NFPA #31 OF THE NATIONAL
FIRE PROTECTION ASSOCIATION AND IN
ACCORDANCE WITH ALL LOCAL, STATE AND
NATIONAL CODES.
Any IN-WARRANTY burner component which is defective
in material or workmanship will be either repaired or
replaced as follows:
1. Fuel units, motors, transformers, gas valves, and
controls should be returned to an authorized service
station or distributor of WAYNE for determination of
applicability of this LIMITED WARRANTY as to either
repair or replacement, where said service station or
distributor is reasonably available in the customer’s
locality. The manufacturers of burner components
regularly publish and distribute listings showing the
locations of their network of service stations. Where
such local service is NOT available for the burner
components described above or other burner parts are
involved, these items should be returned, freight
prepaid, to WAYNE Service Department, 801 Glasgow
Ave, Fort Wayne, Indiana 46803.
2. Burners and/or component(s) determined to be
covered under this LIMITED WARRANTY by WAYNE
shall be repaired or replaced at WAYNE’s sole option.
3. WAYNE is not responsible for any labor cost for the
removal and replacement of said burner or burner
components and equipment associated therewith.
4. A burner so repaired will then carry the LIMITED
WARRANTY equal to the unexpired portion of the
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original burner LIMITED WARRANTY.
5. If inspection by WAYNE does NOT disclose any defect
covered by this LIMITED WARRANTY, the burner or
burner component(s) will be either repaired or
replaced at the expense of the customer and WAYNE’s
regular charges will apply.
6. If the original manufacturer of a burner component
offers a warranty greater than either of our LIMITED
WARRANTIES described above, then this portion will
be added to our LIMITED WARRANTY.
This LIMITED WARRANTY does NOT cover products
which have been damaged as the result of accident,
abuse, misuse, neglect, improper installations, improper
maintenance or failure to operate in accordance with
WAYNE’s written instructions.
These LIMITED WARRANTIES do not extend to anyone
except the first purchaser at retail and only when the
burner is in the original installation site.
IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE SHALL BE
LIMITED TO THE DURATION OF THE LIMITED
EXPRESS WARRANTIES CONTAINED HEREIN. WAYNE
EXPRESSLY DISCLAIMS AND EXCLUDES ANY
LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL
DAMAGES OF ANY NATURE FOR BREACH OF ANY
EXPRESS OR IMPLIED WARRANTY.
Some states do not allow limitation on how long an implied
warranty lasts, so the above limitation may not apply to
you. Also, some states do not allow the exclusion or
limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you.
WAYNE neither assumes or authorizes any person to
assume for WAYNE any other liability or obligation in
connection with the sale of these products. This warranty
gives you specific legal rights, and you may also have
other rights which vary from state to state.
PAGE 20
 CONSUMER INSTRUCTIONS
MAINTENANCE: A dangerous condition has developed and must be corrected.
■ Keep the area around the burner clear and free of com- CONTACT A QUALIFIED SERVICE TECHNICIAN FOR
bustible materials, gasoline or other flammable liquids or CLEANING, READJUSTMENT OR REPAIR.
vapors. Do not obstruct burner air openings or ventilation LIGHTING INSTRUCTIONS:
grilles for combustion air. See Section II Initial Start Up
1. TURN (DEPRESS) VALVE DIAL TO ON.
CAUTION: Check the burner flame periodically. A proper
2. TURN MAIN POWER ON.
NATURAL gas flame will appear blue at the burner face with
3. SET THERMOSTAT OR OPERATING CONTROL TO CALL
orange and yellow tips. A proper PROPANE gas flame will
FOR HEAT.
appear blue at the burner face with yellow tips. If the flame
4. WAIT 30 SECONDS. IF BURNER HAS FAILED TO LIGHT,
is too rich, it will appear billowy and yellow with hazy tips,
OR IF BURNER LIGHTS THEN GOES OUT, TURN
if too lean, it will appear short and all blue. Burner cleaning
BURNER OFF FOR 30 SECONDS AND THEN BACK ON
and/or readjustment is indicated by flames that are too rich
FOR RESTART.
or too lean.
TO SHUT OFF:
WARNING: If any flame is observed when the burner is on
1. TURN (DEPRESS) VALVE DIAL TO OFF.
standby, or if the ignition spark or valve operator is heard to
2. TURN MAIN POWER OFF.
come on before the motor reaches operating speed, im-
mediately turn off the manual gas control and main power.

EXPLOSION HAZARD
If PROPANE gas is used and the burner is located in a
basement, crawlspace or confined space, contact your
gas supplier about installing a “gas leak” warning device.
PROPANE gas is heavier than air and can settle in low
areas or confined spaces. This would create a DANGER
OF EXPLOSION OR FIRE. If you suspect a gas leak,
follow instructions on front cover of this manual.

ELECTRIC SHOCK HAZARD

CARBON MONOXIDE
POISONING HAZARD HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT
FOLLOW THESE RULES TO AVOID ELECTRICAL SHOCK.
CARBON MONOXIDE IS A COLORLESS, ODORLESS GAS
THAT CAN KILL. FOLLOW THESE RULES TO CONTROL ▲ Use only a properly grounded circuit. A ground fault
CARBON MONOXIDE. interrupter is recommended

▲ Do not use this burner if in an unvented, enclosed area.
Carbon monoxide may accumulate.
▲ Do not adjust the pressure regulator. High pressures
produce carbon monoxide.
▲ Do not spray water directly on burner.
▲ Turn off power before servicing.
▲ Read the owner’s manual before using.

▲ Check flue gases for carbon monoxide. This check

requires specialized equipment.

▲ Allow only qualified burner service persons to adjust

the burner. Special instruments and training are
required. OVERHEATING HAZARD
▲ Read the owner’s manual before using.
SHOULD OVERHEATING OCCUR:

Shut off the manual gas control to the appliance

Do not shut off the control switch to the pump or blower.

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 Notes

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